Structure assembly

ABSTRACT

The invention provides a structure that can be moved between storage and erected in-use forms via the use of one or more connecting members. The connecting member can be provided with at least two angularly disposed arms, at least one of the arms provided to receive an edge of a panel of the structure in the erected form. The other arms may receive an edge of another panel or may be formed integrally with a further panel. The structure can be moved between forms without the need for tools.

CROSS REFERENCE TO RELATED APPLICATIONS

This United States Application claims priority to British Patent Application No. 0701218.0 filed 23 Jan. 2007.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not Applicable

BACKGROUND OF THE INVENTION

The invention to which this application relates is to an improvement in structure assemblies, such as toys, pet housing, storage means, and the like, which can be constructed from a “flat pack” form to an in-use, erected form so as to allow the structure to thereafter be used. Typically, the structure can thereafter be moved between the two forms in a manner which can be performed by adults or children in a relatively simple manner and, preferably, without the need for any, or any special, tooling to be used.

Conventionally in structures of this type, the same are typically initially purchased in one of two forms. In the first form, the structure has already been assembled under factory conditions and is therefore provided in a permanent in-use form. This has the advantage that the structures are typically more robust, but for many uses or environments robustness is not the only concern and other concerns, such as the price of the structure which tends to be high when preassembled, and/or subsequent storage of the structure when not in use, are other features which have equal or greater importance to a purchaser. With regard to these features, preassembled structures often are not attractive to a purchaser. An alternative to pre-assembled structures is to purchase the same in pieces in a flat pack form and then to assemble the structure into an erected position after purchase and at the location of use. It is to this type of structure that the present invention is directed.

It is known to provide flat pack structures for assembly at a location for use. The assembly typically involves the use of a series of screws or other fastening means which are required to be inserted in pre-formed apertures in the panels of the structure in accordance with a set of instructions that accompany the structure when purchased. The use of these fastening means typically requires the use of one or more tools which are often required to be provided as part of the package when purchased. This can provide additional expense to the manufacturer and/or customer and, in some instances if the tool is lost, the item cannot thereafter be constructed. Furthermore, if the structure is required to be disassembled for storage purposes, the repeated use of the fastening means can lead to the same becoming damaged and/or lost, thereby preventing the reassembly of the structure.

A further problem which is often experienced with this type of flat pack furniture is that the appearance of the structure, when formed, is affected by the use of the conventional fastening systems. It can be difficult in many cases for the fastening means to be hidden from view in all instances. Furthermore, the panels of sheet material which are used to form the items are often, at best, provided with a continuously and/or repeated patterned surface which, therefore, limits the type of decorative patterns which can be applied to the structure panel. This can often restrict the attractiveness and use of the structure for both purchase and in subsequent use and, therefore, can limit sales of the same.

A first aim of the invention is to provide a structure that can be moved between a storage and an in-use erected form relatively easily, to allow the same to be performed without the need for special tools to be used by the person assembling the same, and to allow the structure, if required, to be repeatedly moved between the storage and in-use forms as required.

A further aim is to provide a structure that is formed of panels with at least one of the panels being provided in a form which has greater visual attractiveness than is typically conventionally achieved, thereby providing an improved visual appearance of the structure, once formed.

BRIEF SUMMARY OF THE INVENTION

In a first aspect of the invention there is provided a structure formed of a plurality of panels. The structure is movable between a storage form in which at least some of the panels are disconnected and a second, erected form for use in which edges of adjacent panels can be connected together to form the structure, wherein at least some of the adjacent edges of the panels are connected using a connecting member. The connecting member has a first arm with a channel formed therein to receive an edge of a first panel therein and at least a second arm including a channel to receive an edge of a second panel therein and thereby retain the first and second panels in an in-use position.

Typically, the first and second arms have an angular displacement which defines the angular orientation of the panels when located with the connecting member.

Typically, the connecting member has a longitudinal axis, and the longitudinal axis of the channels in the first and second arms are parallel therewith. Typically, the first and second channels are separated by a rib which passes along the length of the connecting member, which rib defines a corner of the connecting member.

Typically, a plurality of connecting members are provided as part of the structure at spaced locations, each of the connecting members connecting at least two panels together.

In one embodiment, the connecting member is provided in permanent attachment to one of the panels, typically by the provision of mechanical or adhesive means such that only one panel edge needs to be placed into or removed from the connecting member to assemble or disassemble the structure respectively.

In one embodiment, the connecting member has three or more angularly oriented arms, each having a channel for reception of panel edge therein or attached to or formed as part of a panel.

Typically, the connecting member is of a length that matches the length of at least one of the panel edges to be connected thereby and thereby provides a supported joint along the length of the panels.

In one embodiment, the connecting member is formed from an extruded plastics material.

In one embodiment, at least one of the panels of the structure may be provided with one or more fold lines to allow the panel itself to be folded in the storage position and unfolded, and then connected to at least one further panel using the connecting member in the in-use position.

In a further aspect of the invention, there is provided a structure which can be moved between storage and erected in-use forms. The structure is formed from a plurality of panels which can be interconnected in an erected form and disconnected in the storage form, and wherein at least one of the panels includes, along at least one edge thereof, a connecting member. The connecting member has an arm with a channel provided to receive an edge of one or more further panels to retain the panels in position while the structure is in the erected form.

In one embodiment, the connecting member is provided as an integral formation of one of the panels, typically the panel being formed of molded plastics material with a connecting member formed as part thereof. Alternatively, the connecting member can be attached mechanically or by adhesive to the panel and, hence, allow the edge of a further panel to be selectively placed into the channel in the arm of the connecting member.

In one embodiment, the structure which is formed is a toy model of a type which can be used in a child's playhouse, for example. In an alternative embodiment, the structure is used as pet housing, such as a kennel. In a yet further embodiment, the structure can be used as an item of furniture and/or to provide storage facilities. In each case, it will be appreciated that the structure can be moved between storage and erected in-use conditions easily and efficiently without the need for special tools or any tools to be used. It is also found that the location of the edges of the respective panels in the connecting member and the provision of the connecting member along the length thereof provides sufficient rigidity so as to allow the structure, when in the in-use condition, to be used safely and successfully.

In many uses it is important for the structure's intended use, for example, where the structure is for use as a toy model, that the visual appearance of the structure when in-use gives a desired effect, otherwise the toy model would be unattractive to a child.

In accordance with a further aspect of the invention there is provided a structure. The structure is formed from a plurality of panels, at least one of the panels formed of a sheet material and to at least one side of which is applied a coating and onto which a decorative pattern is printed.

In one embodiment, the sheet material used for the panels is medium density fiber board (MDF) or could be any other suitable sheet material. The coating can be a plastics material applied to a planer surface thereof to seal the same and allow the application of printing inks to preferably be applied using a 4-color printing process. This allows detailed decorative printing to be achieved which, therefore, makes the overall appearance of that panel and the structure as a whole to be more closely related to the item depicted. For example, if the structure is a toy model, the item which the same is intended to depict, such as a sink, washing machine, cooker or the like, can be shown on the printed surface which forms the external surfaces of the structure when in the in-use form.

In one embodiment, a range of the structures can be used in conjunction to form a particular toy model or toy environment, such as, a kitchen, bedroom, or the like.

In a further aspect of the invention there is provided a toy model structure. The structure comprises a top, and one or more side walls depending downwardly from the top to support the top at a distance from a support surface, at least the side walls formed by panels, the panels selectively movable between a storage form in which at least some of the same are disconnected, and an erected in-use form, and wherein in the in-use form the panels are retained in the required configuration by connecting members. The connecting members include at least one arm having a channel for the reception of an edge of a panel therein to thereby retain the panel in position and locate the panel in an angular orientation with respect to a second panel with which the connecting member is connected or formed.

In one embodiment, the connecting member is formed as an integral part of the second panel or, alternatively, an edge of the second panel can be selectively placed into a further arm provided in the connecting member at the required angular orientation to the first arm. In one embodiment a further panel can be permanently maintained with the further arm.

Thus, the structure can be moved between the erected and storage conditions without the need for tools to be used.

In one embodiment, at least one of the panels is formed from a sheet material having at least one laminated surface to which an ink pattern is applied using a 4-color printing process.

In one embodiment, at least one of the panels is formed from a molded plastics material and, in this case, may include connecting members formed as integral parts at the edges thereof.

In a further aspect of the invention there is provided a connecting member. The connecting member being elongate in form and having a first arm running along the length thereof, with a channel provided therein for the reception of an edge of a first panel to retain the same in position and the connecting member provided with a second arm formed as part of or connectable to a further panel so as to retain the respective panels in an angular orientation defined by the orientation of the arms.

In one embodiment, the channel includes therein one or more protrusions to exert an increased retention force on one or more faces of the panel adjacent the edge thereof.

Typically, at least one of the panels can be selectively detached from the connecting member without the need for tools.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific embodiments of the invention are now described with reference to the accompanying drawings.

FIG. 1 illustrates a first embodiment of a connecting member in accordance with the invention.

FIG. 2 illustrates a second embodiment of a connecting member in accordance with the invention.

FIGS. 3 a and b illustrate a first embodiment of use of a connecting member in accordance with the invention.

FIGS. 4 a and b illustrate further embodiments of a structure formed in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1, there is illustrated a connecting member 2 in accordance with one embodiment of the invention. As will be seen, the connecting member is elongate and, in this embodiment, includes first and second arms, 4, 6 which are angularly offset by an angle X, as illustrated. In this case, each of the arms includes a channel, 8, 10 respectively, which runs along the length of the same. The channel 8 of first arm 4 is shown receiving an edge 12 of a first panel 14 which is partially shown, and channel 10 of second arm 6 receives the edge 12 of a second panel 16 which is partially shown. The channels can be provided with retention means, which may be in the form of protrusions 20, which improve retention on one or more faces of the panel at the panel edge so as to improve retention of the panel within the channel. It will, therefore, be seen that by retaining the respective panel edges in the connecting member, the panels can be held in position and in position at a required angular orientation, angle X. The longitudinal axes of the respective channels run parallel to the longitudinal axes 19 of a rib 17 member, the rib separates channels 8, 10.

FIG. 2 illustrates an alternative embodiment of a connecting member 2 in which the same is again provided with a first arm 22 with a channel 24 which operates to receive edge 12 of a first panel 14 as shown. However, a second arm 15 is formed as an integral part of second panel 16 which may be formed, for example, of a plastics material.

In whichever embodiment, it is preferred that only one panel needs to be inserted or attached to allow movement of the structure between storage and erected positions, and in the second embodiment of FIG. 2 this is achieved. In the first embodiment, where both arms receive a panel, this can be achieved by providing one of the panels to be permanently attached within a channel either by, for example, a mechanical connection, or use of adhesive, or simply by leaving one of the panel edges engaged in the channel of one of the arms.

FIGS. 3 a and b illustrate one embodiment of use of the connecting members 2 in accordance with the invention, and it will be seen how each of the connecting members 2 provides support along the length of the edge of the respective panels 26/28, 28/30, 30/32 and 32/28 respectively. In this case, the structure which is formed is a play structure in the form of a toy model, and it will be seen that the connecting members form the four corners of the side walls of the structure and therefore provide a rigid and secure structure for play when in the erected position. Equally, the invention allows the structure to be easily moved to the storage position by disconnection of the panels from the connecting members 2 and therefore allow the panels to be stored in a flat pack form one on top of the other. The panels can also be provided with apertures 34, if this assists the decorative effect which is required to be created. This, therefore, means that the child can gain pleasure from playing with the item but without the potential problem of storage when not in use.

FIGS. 4 a and b illustrate further possible embodiments of the invention and, in this case, connecting members 2 are provided as integral parts of molded panel 36, which forms the top face of the structure and are also provided at the base of the structure. If desired, connecting members can also be used to connect the panels along the vertical edges, although not shown in the diagrams. In the case when used on top panel 36, the connecting members are provided with only one arm 37 with a channel into which the top edges of the side wall panels of the structure are retained. The other arm is provided integrally with top panel 36. In this case, a base 38 is also provided which has a further connecting member 2 formed as apart thereof, or the connecting members may be of the type shown in FIG. 1.

It is a further aspect of the invention that the current invention allows the use of panels which have relatively decorative appearances, as shown in FIGS. 4 a and b. This allows for a particularly attractive and effective visual appearance to be created. In a further embodiment, the panels are formed of MDF which provide the rigidity and strength, and at least the external surface of the same is coated, typically, with a plastic laminate onto which the decorative pattern can be printed, typically, using a 4-color printing process to provide a detailed and attractive visual effect. Furthermore, the panels may be provided with apertures or other patterns to further improve the appearance.

It is, therefore, clear from the present invention as defined that structures can be provided in an in-use condition which is sufficiently strong and rigid so as to allow the same to be used yet also easily moved to a storage position, without the need for tooling or fastening elements and thereby allows the structures to be used, for example, by children and constructed into an in-use position by them without the need for adult intervention which provides greater independence and education to the children. 

1. A structure, said structure formed of a plurality of panels, said structure movable between a storage form in which at least some of the panels are disconnected, and a second erected form for use in which edges of adjacent panels can be connected together to form the structure, wherein at least some of said adjacent edges of the panels are interconnected using a connecting member, said connecting member having a first arm with a channel formed therein to receive an edge of a first panel therein and a second arm including a channel to receive an edge of a second panel and retain the same therein and thereby retain said first and second panels in an in-use position.
 2. A structure according to claim 1 wherein an angular orientation of said first and second arms about a longitudinal axis of said connecting member define an angular orientation of said panels when located with said connecting member.
 3. A structure according to claim 1 wherein said first and second channels are separated by a rib.
 4. A structure according to claim 3 wherein said rib passes along a length of said connecting member.
 5. A structure according to claim 4 wherein said rib defines a corner of said connecting member.
 6. A structure according to claim 1 wherein a plurality of connecting members are provided as part of said structure at spaced locations.
 7. A structure according to claim 1 wherein said connecting member is provided in permanent attachment to one of said panels.
 8. A structure according to claim 1 wherein said connecting member is of a length which matches the length of at least one panel edge to be connected thereby.
 9. A structure according to claim 1 wherein at least one of said panels of said structure is provided with one or more fold lines to allow said panel to be folded in a storage position.
 10. A structure which can be moved between a storage and in-use forms, said structure formed from a plurality of panels which can be interconnected in an erected the in-use form and disconnected in the storage form, and wherein at least one of the panels includes along at least one edge thereof a connecting member, the connecting member having an arm with a channel provided to receive an edge of one or more further panels and retain the panels in position while the structure is in the erected form.
 11. A structure according to claim 10 wherein said connecting member is provided as an integral formation of one of said panels.
 12. A structure according to claim 10 wherein at least one of said panels formed of a sheet material to at least one side of which is applied a coating and onto which a decorative pattern is printed.
 13. A structure according to claim 12 wherein said coating is a plastic material applied to at least one planer surface of the panel.
 14. A structure according to claim 12 wherein the decorative pattern is printed using a 4-color printing process.
 15. A toy model structure, said structure comprising a top and one or more side walls depending downwardly from the top to support the top at a distance from a support surface, at least said side walls formed by panels, said panels selectively movable between a storage form at which at least some of the same are disconnected, and an erected in-use form and wherein in the in-use form the panels are retained in the required configuration by connecting members, said connecting members including at least one arm having a channel for the reception of an edge of a panel therein, to thereby retain said panel in position and locate said panel in an angular orientation with respect to the second panel with which the connecting member is connected or formed.
 16. A structure according to claim 15 wherein said connecting member is formed as an integral part of a further panel.
 17. A connecting member, said connecting member elongate in form and having a first arm running along the length thereof with a channel provided therein for the reception of an edge of a first panel to retain the same in position therewith and said connecting member formed as part of or connected to a second panel so as to retain the respective panels in a required angular orientation.
 18. A connecting member according to claim 17 wherein the channel includes therein one or more protrusions to exert an increased retention portion on one or more faces of the panel adjacent the edge thereof. 